Anti-off invisible sock and manufacturing method thereof

ABSTRACT

This invention provides an anti-off invisible sock and a manufacturing method thereof. The anti-off invisible sock includes a sock body and an anti-slip film. The sock body includes a sock heel, a sock middle section, and a sock toe. The sock heel, the sock middle section, and the sock toe are formed integrally by knitting. The anti-slip film is hot stamped inside the sock heel by heat transfer and it is a polyolefin glue film. The anti-off invisible sock provided by this invention has sufficient elasticity, more closely fitting, and is comfort to wear and uneasy to fall off. Meanwhile, an allergic problem caused by silica gel in the conventional anti-off sock can be effectively avoided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Non-provisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No(s). 2016-215695 filed in Japan on Nov. 2, 2016, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to a sock, and more particularly, to an anti-off invisible sock and method manufacturing method thereof.

Description of the Related Art

With the improvement of people's living standards, people have a higher pursuit of clothing matching. People want not only to wear nice but also to wear comfortable, so invisible socks came into being. Unlike a common sock, the length of the invisible sock is always short, and the rib cuff is often below the ankle. As the first half of foot is usually covered after wearing shoes, socks cannot be seen, and it is visually feels like not wearing socks. This kind of socks is suitable for most of the casual shoes and is beautiful and natural. Meanwhile, the invisible sock covers less and is more comfortable and breathable, which can effectively reduce irritable feverish sensation when doing sports in hot days and avoid embarrassment caused by excessive foot sweat and odor diffusion.

As the height of heel wrapped by the invisible sock is relatively low, the invisible sock can easily fall off during wearer's movement compared to the common sock. In order to prevent the invisible sock from falling off, an anti-slip silica gel strip is hot stamped at the position of the sock heel of the existing invisible sock. Liquid silica gel is adhered inside the sock heel by a screen printing process and then formed the anti-off silica gel strip after high temperature drying. However, since the screen printing process needs to carry out heating and drying, the energy consumption is high, and the pollution is heavy. What's more, mechanical apparatus occupies a large area and costs high labor. At the same time, it is difficult to determine the printing position of the silica gel strip for the screen printing process, and there are defects that dispensing position can be not accurate and the silica gel is easy to foam. In addition, because of the physical properties of the silica gel itself, the thickness of the thinnest film is more than 1 mm (usually within the range of 1 mm-2 mm). The printed silica gel is thick and owns poor slip resistance. It is not conducive to blood circulation as extrusion trace can be left on consumer's skin after the consumer wear these socks. Particularly, many of the existing silica gel is not totally safe and non-toxic, and some people are allergic to the silica gel.

What's more, the conventional invisible sock is poor in elasticity and is uncomfortable to wear. Since many loops are formed by the conventional knitting method when the two sides of the middle section at the bottom are edged, it is unable to control the stretch of the sock, and the sock is easy to fall off.

BRIEF SUMMARY OF THE INVENTION

In order to overcome at least one deficiency of prior art, this invention provides an anti-off invisible sock having an anti-slip film made of a new material and a manufacturing method thereof.

In order to achieve above objective, this invention provides an anti-off invisible sock, including a sock body and an anti-slip film. The sock heel, the sock middle section, and the sock toe are formed integrally by knitting. The anti-slip film is hot stamped inside the sock heel by heat transfer and it is a polyolefin glue film.

In an embodiment of the present invention, both sides of the sock middle section may adopt a picking-inserting-needle combined knit structure, and the picking-inserting-needle combined knit structure may be a combination of picking-needle without forming a loop and inserting-needle with securing a loop.

In an embodiment of the present invention, the sock body may be knitted by an outer yarn and an inner yarn, the outer yarn may adopt JS32S/1 combed cotton, the inner yarns may adopt 40D spandex/70D nylon covered yarn, the sock body may have a rib cuff, and the rib cuff may adopt 180/70/70 lycra.

In order to achieve another objective of this invention, this invention further provides a manufacturing method for the anti-off invisible sock, including: knitting to form the sock body, the sock body comprising the sock heel, the sock middle section, and the sock toe; and hot stamping the polyolefin glue film inside the sock heel by heat transfer to be the anti-slip film.

In an embodiment of the present invention, the heat transfer may be carried out by a turntable hot glue machine.

In an embodiment of the present invention, the temperature of a hot head of the turntable hot glue machine may be between 200° C. and 300° C., the pressure of the heat transfer may be between 0.3 MPa and 0.8 MPa.

In an embodiment of the present invention, the duration of the heat transfer may be between 3 and 10 seconds.

In an embodiment of the present invention, knitting to from the sock body may include adopting a picking-inserting-needle combined knit method to knit the sock middle section, and the picking-inserting-needle combined knit method may be a combination of picking-needle without forming a loop and inserting-needle with securing a loop.

In an embodiment of the present invention, the picking-inserting-needle combined knit method may include taking three loops as a circle to achieve tightening an edge of the sock middle section, after threading a first loop, leaving one stitch without forming a loop for a second loop at the beginning of a threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a third loop at the beginning of the threading position corresponding to each stitch of the first loop, and repeating the above steps for threading.

In an embodiment of the present invention, the picking-inserting-needle combined knit method may include taking three loops as a circle to achieve tightening an edge of the sock middle section, after threading the first loop, leaving one stitch without forming a loop for the second loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving one stitch without forming a loop for the third loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a fourth loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a fifth loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a sixth loop at the beginning of the threading position corresponding to each stitch of the first loop, and repeating the above steps for threading.

In an embodiment of the present invention, knitting to form the sock body may be forming the sock body by knitting an outer yarn and an inner yarn, the outer yarn may adopt JS32S/1 combed cotton, the inner yarn may adopt 40D spandex/70D nylon covered yarn, the sock body may have a rib cuff, and the rib cuff may adopt 180/70/70 lycra.

In summary, the anti-slip film of the anti-off invisible sock provided by this invention is the polyolefin glue film instead of a conventional silica gel strip. The polyolefin glue film is non-toxic and harmless. It will not cause an allergic inflammation problem when a consumer's skin contacts the polyolefin glue film. Meanwhile, the problem of falling off easily can also be solved when the invisible socks are worn. Particularly, the invention adopts the polyolefin glue film as the anti-slip film, and hot stamps the polyolefin glue film inside the sock heel instead of adhering by a screen printing process, thereby greatly reducing production consumption, saving energy, and protecting environment. It is easy to operate and can reduce labor cost significantly. What's more, the position of hot stamping is accurate, and the polyolefin glue film formed by hot stamping is thin, flexible, smooth and more comfortable for wearing.

In addition, the anti-off invisible sock and the manufacturing method thereof in this invention adopts a special knitting method for tightening the edging of the sock middle section. In this way, the stretch of the sock body can be controlled, and it is uneasy to fall off when the sock is worn. Meanwhile, the flexibility of the sock itself can be ensured. It is more closely fitting and comfortable.

What's more, by using the specific materials for the outer yarn, the inner yarn and the rib cuff, the stretch and fitting of the sock can be further controlled through the matching of these fabrics.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a structure schematic diagram of an anti-off invisible sock provided in an embodiment of the present invention;

FIG. 2 is a schematic diagram of a picking-inserting-needle combined knit structure provided in an embodiment of the present invention;

FIG. 3 is a partial enlarged view of FIG. 2;

FIG. 4 is a knitting schematic diagram of FIG. 2;

FIG. 5 is a schematic diagram of a picking-inserting-needle combined knit structure provided in another embodiment of the present invention; and

FIG. 6 is a knitting schematic diagram of FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, this invention provides an anti-off invisible sock, including a sock body 1 and an anti-slip film 5. The sock body 1 includes a sock heel 4, a sock middle section 3, and a sock toe 2. The sock heel 4, the sock middle section 3, and the sock toe 2 are formed integrally by knitting. The anti-slip film 5 is hot stamped inside the sock heel 4 by heat transfer and is a polyolefin glue film.

The sock body 1 has a rib cuff 6. In order to achieve the effect of invisible beauty, the position of the rib cuff 6 is relatively low. To prevent the sock from falling off, the common practice in this art is to adhere an anti-slip film inside the sock heel. The anti-slip film of the conventional invisible sock adopts silica gel as a raw material. Liquid silica gel is printed inside the sock heel by a screen printing process and then is solidified to form an anti-off silica gel strip after high temperature drying. The drawback is that the silica gel strip is thick, poor in elasticity, weak in anti-off performance, and easy to fall off. Further, because of the physical properties of the silica gel itself, the thickness of the thinnest film should be more than 1 mm (usually within 1-2 mm). A consumer feels squeezing after wearing. In addition, as most people are allergic to the silica gel, wearing comfort is greatly reduced. What's more, there are drawbacks such as large power consumption and heavy pollution in the production process.

The anti-slip film 5 of this invention is prepared from polyolefin (abbreviated as PO, which may be polyethylene, polypropylene, or a polymer of ethylene, propylene and other higher olefins). In practical applications, a small amount of polyethylene terephthalatecan (abbreviated as PET) can be doped, so that polyethylene terephthalate can form a protective layer after polyolefin forms the polyolefin glue film. The anti-slip film 5 is hot stamped inside the sock heel by heat transfer, replacing the silica gel which may cause allergies. A dispenser used in the conventional screen printing process needs to conduct a high temperature drying to solidify the silica gel, and consequently the power is relatively large and the power demand corresponding to manufacturing each pair of socks is 20.83 watts; by adopting the polyolefin materials, there is no need of high temperature drying procedure in the manufacture process, and the polyolefin materials can be molded and fixed directly on the socks through hot stamping. The power demand corresponding to manufacturing each pair of socks is 1.11 watts, saving nearly 95% energy consumption. The difference of energy consumption is nearly 19 times, which is highly energy saving and environmentally protective. In addition, due to the high mechanical strength of the polyolefin itself, the thinnest glue film made of the polyolefin can reach 0.2 mm in thickness. Thus, the wearer almost has no squeezing feeling after wearing the socks, and the degree of comfort is quite high.

In the present embodiment, both sides of the sock middle section 3 adopt a picking-inserting-needle combined knit structure, and the picking-inserting-needle combined knit structure is a combination of picking-needle without forming loops and inserting-needle with securing loops. The picking-inserting-needle combined knit structure in this invention will be illustrated in detail with combination to the manufacturing method hereinafter.

This invention also provides a method for manufacturing an anti-off invisible sock, including: knitting to form the sock body 1, the sock body including the sock heel 4, the sock middle section 3, and the sock toe 2; and hot stamping the polyolefin glue film inside the sock heel 4 by heat transfer to be used as the anti-slip film 5.

In the present embodiment, the heat transfer is carried out by a turntable hot glue machine. The principle of the turntable hot glue machine is heating a hot stamping mold by a heating module, and after reaching a set temperature, an adhesive strip melts and adheres to the product through pressing a substrate by a cylinder. The turntable hot glue machine adopts a pneumatic automatic principle, a turntable table adopts a sealing cutter in high precision to control accurate positioning, and the equipment adopts Omron electronically controlled components to precisely control circuit structures, thereby making the equipment more accurately controlled and have a longer service life. A glue recycling device uses the engagement of glue rollers to recycle, ensuring the precision of winding at the highest level.

Parameters of the turntable hot glue machine: power supply 220V 50 HZ; power heating 400 W motor 250 W; maximum temperature 300° C.; hot stamping delay 0-25 secs; gross weight 280 KG; model size 1378*758*830 mm. The area occupied by the turntable hot glue machine occupies is smaller than that occupied by the screen printing machine equipment, the operation is simpler, and less labor is required. At the same time, the power is small, and the turntable hot glue machine is energy saving and environmentally protective.

In the present embodiment, the temperature of a hot head of the turntable hot glue machine is between 200° C. and 300° C., and the pressure of hot stamping is between 0.3 MPa and 0.8 MPa. Preferably, the temperature of the hot head of the turntable hot glue machine is between 200° C. and 230° C., and the pressure of hot stamping is 0.5 MPa. In the present embodiment, the duration of the heat transfer is between 3 seconds and 10 seconds. Preferably, the duration of the heat transfer is 5 seconds. By setting the above parameters, it can not only guarantee that the polyolefin glue film can be bonded firmly inside the sock heel 4, but also ensure that the thickness of the formed glue film is uniform and thin, with high smoothness, comfort, and no excessive waste of energy consumption. The word “between” mentioned in this invention includes the two endpoint values.

In the present embodiment, knitting to from the sock body 1 comprises adopting a picking-inserting-needle combined knit method to knit the sock middle section 3, and the picking-inserting-needle combined knit method is a combination of picking-needle without forming loops and inserting-needle with securing loops. In details, both sock edges 7 of the sock middle section 3 adopt the picking-inserting-needle combined knit structure. The picking-inserting-needle is picking the needle without engaging a yarn, and then inserting the needle to engage the yarn to adjust looping to control the knitting knot. Please refer to FIG. 3. FIG. 3 is an enlarged view of the knit structure at the sock edge 7. The sock edge 7 reduces looping by combining the picking-needle and the inserting-needle and gradually reduces looping from inside to outside, thereby tightening the two sides of the sock. The transition from the picking-inserting-needle combined knit structure of the sock edge 7 to traditional plain stitch of the rib cuff 6 is realized by controlling the feeding of the needle. It can effectively control the stretch of the sock body 1 through this kind of knit structure. In this way, the sock is fitting and will not wrinkle, neither friction damage nor squeezing wrinkle will occur, and the rib cuff 6 will not fall off due to being too loose.

Please refer to FIG. 2 to FIG. 4. The area of 0 in FIG. 4 represents not forming a loop (no looping), and the area of 1 represents forming a loop (looping). One method for picking-inserting-needle combined knit structure is taking three loops as a circle to achieve tightening the edge of the sock edge 7. After threading the first loop (the needle count of full loops is settled based on specific conditions, and the needle count of full loops for every single circle is the same), leave one stitch without forming a loop for a second loop at the beginning of a threading position corresponding to each stitch of the first loop, and leave consecutive two stitches without forming loops for a third loop at the beginning of the threading position corresponding to each stitch of the first loop. Then insert the picked needle and thread the fourth loop, and repeat the above steps.

Please refer to FIG. 5 and FIG. 6. The area of 0 in FIG. 6 represents not forming a loop (no looping), and the area of 1 represents forming a loop (looping). Another method for picking-inserting-needle combined knitting is taking six loops as a circle to achieve tightening the edge of the sock edge 7. After threading the first loop (the needle count of full loops is settled based on specific conditions, and the needle count of full loops for every single circle is the same), leave one stitch without forming a loop for the second loop at the beginning of the threading position corresponding to each stitch of the first loop, leave one stitch without forming a loop for the third loop at the beginning of the threading position corresponding to each stitch of the first loop, leave consecutive two stitches without forming loops for a fourth loop at the beginning of the threading position corresponding to each stitch of the first loop, leave consecutive two stitches without forming loops for a fifth loop at the beginning of the threading position corresponding to each stitch of the first loop, leave consecutive two stitches without forming loops for a sixth loop at the beginning of the threading position corresponding to each stitch of the first loop. Then insert the picked needle and thread the seventh loop, and repeat the above steps.

By taking any of the above-mentioned method of picking-inserting-needle combined knitting for tightening the edge, the overall stretch control and elasticity can reach the maximum balance. Other methods for picking-inserting-needle combined knitting can lead to the result that the sock is easily too loose or too tight or that the bearing strength is too small, and the knit structure can be broken if the stretching force is too large.

The above embodiments and the accompanied drawings are for ease of understanding and is not for limiting the existed form of the picking-inserting-needle combined knitting. Any knitting method, which can achieve the function of tightening the sock edge by reducing looping by picking-needle and securing the loops by inserting-needle at the sock body 1 thus to reduce looping at the sock edge, should be considered as a simple modification to the present invention. By using the picking-inserting-needle combined knitting method, the looping of the sock edge 7 can be reduced, the knitting structure of the sock edge is tighten, and the wearing is more fit.

In the present embodiment, the sock body 1 is knitted by an outer yarn and an inner yarn, the outer yarn adopts JS32S/1 combed cotton, the inner yarn adopts 40D spandex/70D nylon covered yarn, and the rib cuff 6 adopts 180/70/70 lycra. The stretch and fitting of the sock can be further controlled through the matching of these fabrics. The sock body 1 has enough flexibility and comfort and it is relatively easy to wear and take off through the combining and matching of these fabrics. Meanwhile, the material texture is very soft and there is no squeezing nor stimulation. In order to facilitate manufacture processing and improve the strength of organization, a rubber band is knitted and fixed inside the rib cuff 6 through a plain knit organization by an outer yarn and a covered yarn.

In summary, the anti-slip film of the anti-off invisible sock provided by this invention is the polyolefin glue film instead of a conventional silica gel strip. The polyolefin glue film is non-toxic and harmless. It will not cause an allergic inflammation problem when a consumer's skin contacts the polyolefin glue film. Meanwhile, the problem of falling off easily can also be solved when the invisible socks are worn. Particularly, the invention adopts the polyolefin glue film as the anti-slip film, and hot stamps the polyolefin glue film inside the sock heel instead of adhering by a screen printing process, thereby greatly reducing production consumption, saving energy, and protecting environment. It is easy to operate and can reduce labor cost significantly. What's more, the position of hot stamping is accurate, and the polyolefin glue film formed by hot stamping is thin, flexible, smooth and more comfortable for wearing.

In addition, the anti-off invisible sock and the manufacturing method thereof in this invention adopts a special knitting method for tightening the edging of the sock middle section. In this way, the stretch of the sock body can be controlled, and it is uneasy to fall off when the sock is worn. Meanwhile, the flexibility of the sock itself can be ensured. It is more closely fitting and comfortable.

What's more, by using the specific materials for the outer yarn, the inner yarn and the rib cuff, the stretch and fitting of the sock can be further controlled through the matching of these fabrics.

Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, the disclosure is not for limiting the scope of the invention. Persons having ordinary skill in the art may make various modifications and changes without departing from the scope and spirit of the invention. Therefore, the scope of the appended claims should not be limited to the description of the preferred embodiments described above. 

What is claimed is:
 1. An anti-off invisible sock comprising: a sock body, including a sock heel, a sock middle section, and a sock toe, the sock heel, the sock middle section, and the sock toe being formed integrally by knitting; and an anti-slip film, hot stamped inside the sock heel by heat transfer and being a polyolefin glue film
 2. The anti-off invisible sock according to claim 1, wherein both sides of the sock middle section adopt a picking-inserting-needle combined knit structure, and the picking-inserting-needle combined knit structure is a combination of picking-needle without forming a loop and inserting-needle with securing a loop.
 3. The anti-off invisible sock according to claim 1, wherein the sock body is knitted by an outer yarn and an inner yarn, the outer yarn adopts JS32S/1 combed cotton, the inner yarn adopts 40D spandex/70D nylon covered yarn, the sock body has a rib cuff, and the rib cuff adopts 180/70/70 lycra.
 4. A method for manufacturing an anti-off invisible sock according to claim 1, comprising the following steps: knitting to form the sock body, the sock body comprising the sock heel, the sock middle section, and the sock toe; and hot stamping the polyolefin glue film inside the sock heel by heat transfer to be the anti-slip film.
 5. The method for manufacturing the anti-off invisible sock according to claim 4, wherein the heat transfer is carried out by a turntable hot glue machine.
 6. The method for manufacturing the anti-off invisible sock according to claim 5, wherein a temperature of a hot head of the turntable hot glue machine is between 200° C. and 300° C., and a pressure of the heat transfer is between 0.3 MPa and 0.8 MPa.
 7. The method for manufacturing the anti-off invisible sock according to claim 4, wherein duration of the heat transfer is between 3 seconds and 10 seconds.
 8. The method for manufacturing the anti-off invisible sock according to claim 4, wherein knitting to from the sock body comprises adopting a picking-inserting-needle combined knit method to knit the sock middle section, and the picking-inserting-needle combined knit method is a combination of picking-needle without forming a loop and inserting-needle with securing a loop.
 9. The method for manufacturing the anti-off invisible sock according to claim 8, wherein the picking-inserting-needle combined knit method comprises taking three loops as a circle to achieve tightening an edge of the sock middle section, after threading a first loop, leaving one stitch without forming a loop for a second loop at the beginning of a threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a third loop at the beginning of the threading position corresponding to each stitch of the first loop, and repeating the above steps for threading.
 10. The method for manufacturing the anti-off invisible sock according to claim 8, wherein the picking-inserting-needle combined knit method comprises taking three loops as a circle to achieve tightening an edge of the sock middle section, after threading the first loop, leaving one stitch without forming a loop for the second loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving one stitch without forming a loop for the third loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a fourth loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a fifth loop at the beginning of the threading position corresponding to each stitch of the first loop, leaving consecutive two stitches without forming loops for a sixth loop at the beginning of the threading position corresponding to each stitch of the first loop, and repeating the above steps for threading.
 11. The method for manufacturing the anti-off invisible sock according to claim 4, wherein knitting to form the sock body is forming the sock body by knitting an outer yarn and an inner yarn, the outer yarn adopts JS32S/1 combed cotton, the inner yarn adopt 40D spandex/70D nylon covered yarn, the sock body has rib cuff, and the rib cuff adopts 180/70/70 lycra. 